Disassembly and Reassembly
DISASSEMBLY
1. REMOVE HEATER TO REGISTER DUCT CENTER
a. Release the 4 claws and remove the heater to register duct center.
2. REMOVE AIR OUTLET CONTROL SERVO MOTOR
a. Remove the 3 screws and air outlet control servomotor.
3. REMOVE AIR MIX CONTROL SERVO MOTOR
a. LH side:
Remove the 3 screws and air mix control servomotor.
b. RH side:
Remove the 3 screws and air mix control servomotor.
4. REMOVE EVAPORATOR TEMPERATURE SENSOR
a. Release the clamp and connector.
b. Release the 2 claws and remove evaporator temperature sensor.
5. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Remove the 2 screws and piping cover.
b. Remove the screw and bracket.
c. Remove the heater radiator unit sub-assembly.
NOTE: Prepare a drain pan or cloth for cooling water leaks.
6. REMOVE AIR CONDITIONING TUBE ASSEMBLY
a. Remove the packing.
b. Using a hexagon wrench 4.0 mm, remove the 2 hexagon bolts and air conditioning tube assembly.
c. Remove the 2 O-rings from the air conditioning tube assembly.
7. REMOVE COOLER EXPANSION VALVE
a. Remove the cooler expansion valve from the cooler evaporator sub-assembly No. 1.
8. REMOVE COOLER EVAPORATOR NO.1 SUB-ASSEMBLY
a. Remove the 3 screws and air duct sub-assembly.
b. Release the 4 claws and remove the air duct sub-assembly.
c. Remove the 11 screws and separate the heater case.
d. Remove the cooler evaporator No. 1 sub-assembly.
e. Remove the 2 O-rings from the cooler evaporator No. 1 sub-assembly.
REASSEMBLY
1. INSTALL COOLER EVAPORATOR NO.1 SUB-ASSEMBLY
a. Sufficiently apply compressor oil to 2 new O-rings and fitting surface of the cooler expansion valve.
Compressor oil: ND-OIL 11 or equivalent
NOTE:
- Do not use any compressor oil other than ND-OIL 11 or equivalent.
- If any compressor oil other than ND-OIL 11 equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.
b. Install the 2 O-rings on the cooler evaporator No. 1 sub-assembly.
c. Install the cooler evaporator No. 1 sub-assembly the heater case.
d. Install the heater case with the 11 screws.
e. Install the air duct sub-assembly with the 4 claws.
f. Install the air duct sub-assembly with the 3 screws.
2. INSTALL COOLER EXPANSION VALVE
a. Install the cooler expansion valve to the cooler evaporator No. 1 sub-assembly.
3. INSTALL AIR CONDITIONING TUBE ASSEMBLY
a. Sufficiently apply compressor oil to 2 new O-rings and fitting surface of the air conditioning tube assembly.
Compressor oil: ND-OIL 11 or equivalent
NOTE:
- Do not use any compressor oil other than ND-OIL 11 or equivalent.
- If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.
b. Install the 2 O-rings on the air conditioning tube assembly.
c. Using a hexagon wrench 4.0 mm, install the air conditioning tube assembly with the 2 hexagon bolts.
Torque: 3.5 N.m (35 kgf.cm, 30 in.lbf)
d. Install a new packing.
NOTE:
- Be sure to install the packing securely so that there is no clearance.
- Wrap the packing with a shop rag or a piece of cloth as shown in the illustration to prevent moisture from entering.
4. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
a. Install the heater radiator unit sub-assembly.
b. Install the bracket with the screw.
c. Install the piping cover with the 2 screws.
5. INSTALL EVAPORATOR TEMPERATURE SENSOR
a. Engage the 2 claws to install the evaporator temperature sensor.
b. Engage the clamp to install the connector.
6. INSTALL AIR MIX CONTROL SERVO MOTOR
a. LH side:
Install the air mix control servomotor with the 3 screws.
b. RH side:
Install the air mix control servomotor with the 3 screws.
7. INSTALL AIR OUTLET CONTROL SERVO MOTOR
a. Install the air outlet control servomotor with the 3 screws.
8. INSTALL HEATER TO REGISTER DUCT CENTER
a. Engage the 4 clamps to install the heater to register duct center.